WASTE WATER TREATMENT for surface treatment applications

Transcription

1 WASTE WATER TREATMENT for surface treatment applications

2 Effluent an important cost factor Effluent cannot be avoided Water and compound are essential for vibratory mass finishing. During the finishing process the process water is polluted with fines from the media, metal fines and oil. For this reason, the process water must be cleaned before going to drain or being recycled to the finishing machine. The idea to constantly recycle the effluent from mass finishing operations in a "closed loop" system is both ecological and economical. It saves not only water but also compound. In addition, it also saves disposal cost. With most mass finishing applications recycling is possible. Occasionally, there are applications where recycling is not advisable: For example pickling with acid or using several compounds in one process, or the parts surface must be extremely clean. In such applications, a "single pass" system including flocculation and transfer directly to drain is the best alternative for treating the effluent. Flocculation process Flocculation Workpieces Massfinishing machine Drier Effluenttank Flocculation plant Flocculants Sludge thickening filter press Sludge Sewage system By flocculation, contaminants like media and metal fines, metal in solution and oil, are removed from the effluent. After flocculation the water can be discharged to drain in full compliance with legal requirements. Unfortunately, with this treatment method, the compound used in the finishing process is also lost and must be continuously replaced! Centrifugal recycling Workpieces Massfinishing machine Drier Processwater Flocculants (optional) Centrifuge EFfluenttank Processwatertank Sludge Compound Water Recycling with centrifuges In recycling applications media and metal fines are removed from the process water with a centrifuge. Oil and/or extremely fine solids 1µ can be removed by adding flocculants. The compound utilized for the finishing operation remains largely in the process water for reuse in the finishing machine. 02

3 Trowalpur flocculation for complete water cleaning GA 10 - Fully Automatic Crystal clear water All effluents from mass finishing acidic or alkaline can be transformed into clear water with a trowalpur flocculation system. The clear water is in full compliance with legal requirements for discharge to drain. Simple powder flocculation If the daily quantity of produced effluent is no larger than 3000 l, it can easily be cleaned in an economical, easy to operate batch system of the type RT. During the finishing operation the effluent is collected in a collecting tank with stirrer. After work flocculation powder is added. Within a short time flocs are formed and sink to the bottom of the tank. They are automatically filtered during the night via filter bags or a filter press. Automatic flocculation The fully automatic, PLC-controlled Trowalpur GA and DO-systems have a capacity of up to 2000 litres per hour. They are used in larger mass finishing operations. They have been successfully developed over many years and they process batch by batch without the need for an operator. Automatic control and monitoring functions guarantee a stable and safe effluent cleaning process. RT 05-semi-automatic machine Fully automatic machine DO 03 GA 05 GA 10 GA 20 Connected loads (kva) Capacity (ltr/h) Dimension (mm) (L x B x H) 1600 x 2000 x x 2000 x x 2000 x x 2200 x 2800 Sludge thickening filterpress filterpress filterpress filterpress Semi-automatic machine RT 05 RT 10 RT 20 RT 30 Connected loads (kva) 2, ,5 Capacity (ltr/h) Dimension (mm) (L x B x H) 2000 x x 1310 Ø 1600 x 2000 reactor Ø 2000 x 2000 reactor Ø 2200 x 2200 reactor Sludge thickening filter stand filter stand/filterpress filter stand/filterpress filter stand/filterpress 03

4 Centrifugal technology the easy cleaning method With the centrifugal technology solid fines are removed from the process water with a centrifugal force which is 2417 times greater than the gravity of the earth. Basket Centrifuge ZM Peeling pipe Cleaned process water Effluent to be cleaned "ZM 03 ECO" 1 and "ZM 03 FL" are easy to operate, robust systems with manual removal of the sludge basket from the centrifuge. During one cycle 14 litres (19 kg) of sludge can be removed from the effluent. Sludge Sludge basket Functional sketch of a basket centrifuge Basket Centrifuge ZM 03-ECO The solution for the use of up to two vibrators with standard applications and isolated mass finishing applications. Basket Centrifuge ZM 03-FL The universal solution, which can be upgraded retrospectively with process specific options such as pump stations, dosing units, cooling systems and fully automated, un-manned, operation. ZM 03-ECO 1 ZM 03-FL Capacity (ltr/h) Sludge volumen (ltr) Centrifugal rating (g) Mud water tank (ltr) Process water tank Overall dimension (mm) (L x B x H) 1300 x 900 x x 1015 x 1450 Connected loads (kva) 6 6 Motor power-average (kw) 1,5 1,5 04

5 Automatic Centrifuges ZA Cleaned processwater Effluent to be cleaned Deposited sludge Peeling knife The PLC-controlled, automatic ZA centrifuges can clean up to 2 m 3 of effluent per hour. The sludge deposited on the wall of the rotating drum is automatically removed with a "peeling" knife and dropped into a sludge container according to preset time intervals. Due to modular construction many variants of the system are possible and a completely tailored solution can therefore be provided to suit various process requirements. Functional sketch of an automatic centrifuge Application limits Not every mass finishing application is suitable for effluent cleaning with centrifuges. Their use is limited with the following operations: For chemically acceleratedprocesses and paste treatment With multistage finishing, using more than one compound When pickling with strong acids With ball burnishing applications Peeling Centrifuge ZA 04 Peeling Centrifuge ZA 06 ZA 04 ZA 06 Capacity (ltr/h) Sludge volumen (ltr) Centrifugal rating (g) Mud water tank (ltr) Process water tank Drive technology Direct drive V-belt drive Overall dimensions (mm) (L x B x H) 2100 x 1650 x x 2150 x 2300 Connected loads (kva) Motor power-average (kw)

6 Advice for everyday operation Recycling For recycling operations special flocculants are available. They clean the process water in accordance with the requirements for the cleanliness of the parts. Application For ferrous metals For non-ferrous metals Compound Flocculant* Much oil & few fines DE 97 KFL ESM Much oil & many fines or very clean parts required DE 97 KFL R ESM No oil & many fines (plastic or metal parts) KS 66 KS 66 R V No oil/few fines or only ceramic fines KR 50 KS 66 KFL ESM R ESM Magnesium no only Mg MJ 20 not required * Flocculation gives the best results when hot air drying operations exist and / or the components contain oil. Discharging to drain Only the selection of the right flocculant guarantees clean and clear water in compliance with the legal requirements. Machine Flocculant Dosing GA / DO LAC with F (liquid) automatic RT ESM or ESB (powder) manual Sludge analysis of 1 kg of worn media The volume of sludge generated in a mass finishing process depends on the media consumption and the type of effluent treatment. Treatment Ceramic Media Plastic Media Mass (kg) Percentage of Water (%) Volume (L) Mass (kg) Percentage of Water (%) Voume (L) Centrifuge 1, ,95 1,8 45 1,4 Filter press -LAC-Flocculation -ESM-Flocculation 1,9 2, ,45 1,6 2,3 2, ,2 Filter bag 3,1 60 2,6 4,2 70 3,9 06

7 Further applications for Trowal centrifuges Besides mass finishing operations Trowal centrifuges can be utilized for removal of solid fines from the following process liquids: Effluent from paint rooms Phosphating baths Coolants for machining (e.g. grinding machines) Recycling water in wet blasting applications Recycling water for lapping operations Process water for glass grinding Process water for industrial washing machines (degreasing) Functional principle of the centrifugal recycling Clean Process Water Consumer Dirty Water Dirty Water Dirty Water Tank Customer support The Trowal team supports you with a wide range of service functions Expert advice, selection of the right effluent treatment system, quick trouble shooting and maintenance service ensure that your surface finishing operation runs trouble-free without costly downtime. Expert advice regarding your waste water treatment problems by our specialists Preparation of tailor-made plant layouts Chemical analysis of effluent samples in our chemical lab Environmentally safe disposal of your sludge (only in selected countries!) 07

8 MASS FINISHING SHOT BLASTING COATING OF SMALL PARTS EFFLUENT TREATMENT Walther Trowal GmbH & Co. KG Rheinische Str D Haan Tel.: +49(0) Fax: +49(0) Internet: Technical modifications reserved 01/ 06